Working method using sensor and working system for performing same

ABSTRACT

Disclosed is a working method using a sensor, which increases recognition of a component to increase mounting of a component and enhancing productivity. The working method includes: extracting an object to be picked from a pile of objects using the sensor; picking the extracted object to move the picked object to a predetermined place; and estimating an angle of the moved object in the current position using the sensor. Accordingly, the working method can perform precise component recognition and posture estimation by two steps: a component picking step and a component recognition step, and effectively apply to a manufacturing line, thereby improving mounting of a component and enhancing productivity of a product.

CLAIM FOR PRIORITY

This application claims priority to Korean Patent Application No. 10-2012-0109982 filed on Oct. 4, 2012 in the Korean Intellectual Property Office (KIPO), the entire contents of which are hereby incorporated by reference.

BACKGROUND

1. Technical Field

Example embodiments of the present invention relate to an automatic working method using a sensor, and more specifically, to a working method using a sensor, which can improve mounting of a component and enhance productivity of a product, and a working system for performing the same.

2. Related Art

Industrial robots were appeared since 2000 and have been used as an effective means for solving challenges in industrial sites, such as automation tasks, production cost saving, delivery shortage, workforce reduction, etc., and enhancing competitiveness of production systems.

Industrial robots have been started to be introduced in a working environment in which it is difficult for a person to perform works, applied to a vehicle spot welding process, a painting process, and so on and thus used in an automobile industry, a general industry, and a variety of domestic and foreign applications.

Specifically, as performance in a vision sensor technology is developed, among robots being introduced in a manufacturing line, a workpiece automatic installation robot for supplying a machine tool with workpieces disposed around the robot by putting the workpieces one by one in cooperation with a vision sensor has been developed.

Also, even in a machine component assembly process which had a low rate of automation, industrial robots are introduced to perform works at a manufacturing line instead of skilled workers using various IT technologies and elements technologies such as a variety of sensors (for example, a vision sensor, a force sensor, etc.), a control technology, a machine technology, etc.

Also, as a sensing technology among element technologies applied to an industrial robot is enhanced and thus performance in a three-Dimensional visual sensor is also significantly improved, a need to develop an intelligent robot capable of performing a bin-picking work in which a needed component is recognized and picked from a stacked pile is being increased.

However, a visual recognition method or technology applicable to the bin-picking work is not yet applied to the manufacturing line because the visual recognition method or technology is not yet developed sufficiently and has low recognition.

Also, an existing bin-picking method includes a method of extracting polygonal and circular components of an object from a stereo image, a method using a camera image and a CAD model, and a method for modeling a 2-D curved surface with both laser measurement and video images to recognize a position and direction of a 3-D object.

However, it is actually difficult to estimate accurate angles of components disposed at a variety of angles in piles and illuminations changed according to an actual production environment.

SUMMARY

Accordingly, example embodiments of the present invention are provided to substantially obviate one or more problems due to limitations and disadvantages of the related art.

Example embodiments of the present invention provide a working method using a sensor for improving recognition of a component and enhancing productivity of a product.

Example embodiments of the present invention also provide a working system for performing the working method using the sensor.

In some example embodiments, an automatic working method using a sensor includes: extracting an object to be picked from a pile of objects using a sensor; picking the extracted object to move the picked object to a predetermined place; and estimating an angle of the moved object in the current position using the sensor.

The extracting of the object to be picked may include: acquiring an image and depth information of the pile of objects using a visual sensor; extracting a region of the object to be picked using the acquired image and depth information of the pile of objects; calculating a local point of the extracted region of the object to measure a distance to the extracted object using a distance sensor; and picking the extracted object on the basis of the measured distance to move the picked object to a predetermined place.

The extracting of the region of the object may include extracting the region of the object in a model most similar to a standard model in which there is no change in angle in x-axis, y-axis, and z-axis directions, respectively, using the acquired image and depth information of the object.

The estimating of an angle of the moved object using the sensor may include: acquiring an image of the moved object in the current position using the sensor; detecting an edge of the object from the acquired image; extracting a feature of the detected edge; and comparing the extracted feature of the edge with a predetermined object standard model to estimate the angle of the moved object in the current position.

The detecting of an edge of the object from the acquired image may include detecting an edge of the object by performing an image smoothing process on the acquired image and applying adaptive binarization and second derivative to a local region.

The extracting of a feature of the detected edge may include: normalizing the detected edge; and extracting statistical and structural features on the basis of at least one of a pixel distribution of a region of the object, a distance between the distributed pixels of the object, and the number of cross points with respect to the detected local region of the edge.

In other example embodiments, an automatic working system using a sensor comprising: a pile image acquisition unit configured to acquire and provide an image and depth information of a pile of objects using a visual sensor; a processing unit configured to extract a region of at least one object to be picked using the acquired and provided image and depth information of the objects, calculate a local point of the extracted region of at least one object, measure a distance to the at least one object using the sensor, and provide the measured distance; a picking unit configured to pick the at least one object on the basis of the measured distance, which is provided, to move the at least one object to a predetermined place; an object image acquisition unit configured to acquire an image of the moved object; and an object recognition unit configured to detect an edge of the object from the acquired image of the object, extract a feature of the detected edge, compare the extracted feature with a predetermined object standard model, and estimate an angle of the picked object in the current position.

The pile image acquisition unit may extract a region of the at least one object in a model most similar to a standard model in which there is no change in angle in x-axis, y-axis, and z-axis directions, respectively, using the acquired and provided image and depth information of the object.

The object recognition unit may detect an edge of the object by performing an image smoothing process on the image of the moved object and applying adaptive binarization and second derivative for a local region.

The object recognition unit may normalize the detected edge and extract statistical and structural features on the basis of at least one of a pixel distribution of a region of the object, a distance between the distributed pixels of the object, and the number of cross points with respect to the detected local region of the edge.

BRIEF DESCRIPTION OF DRAWINGS

Example embodiments of the present invention will become more apparent by describing in detail example embodiments of the present invention with reference to the accompanying drawings, in which:

FIG. 1 is a conceptual view illustrating an operating environment of an automatic working system using a sensor according to an embodiment of the present invention;

FIG. 2 illustrates an image of a pile of components, which is acquired through a visual sensor according to an embodiment of the present invention;

FIG. 3 is a flowchart illustrating a process of an automatic working method using a sensor according to an embodiment of the present invention;

FIG. 4 is a flowchart illustrating a process of extracting a component picked according to an embodiment of the present invention;

FIG. 5 is a flowchart illustrating a process of estimating posture of a component moved according to an embodiment of the present invention;

FIG. 6 is a flowchart illustrating a process of extracting a feature of an edge detected during the process of estimating posture of a moved component of FIG. 5; and

FIG. 7 is a block diagram illustrating a configuration of an automatic working system using a sensor according to an embodiment of the present invention.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Since the present invention may have diverse modified embodiments, preferred embodiments are illustrated in the drawings and are described in the detailed description of the invention.

However, it should be understood that the particular embodiments are not intended to limit the present disclosure to specific forms, but rather the present disclosure is meant to cover all modification, similarities, and alternatives which are included in the spirit and scope of the present disclosure.

Relational terms such as first, second, and the like may be used for describing various elements, but the elements should not be limited by the terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the present invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.

In the following description, the technical terms are used only for explaining a specific exemplary embodiment while not limiting the present disclosure. The terms of a singular form may include plural forms unless referred to the contrary. The meaning of ‘comprise’, ‘include’, or ‘have’ specifies a property, a region, a fixed number, a step, a process, an element and/or a component but does not exclude other properties, regions, fixed numbers, steps, processes, elements and/or components.

Unless terms used in the present disclosure are defined differently, the terms may be construed as meaning known to those skilled in the art. Terms such as terms that are generally used and have been in dictionaries should be construed as having meanings matched with contextual meanings in the art. In this description, unless defined clearly, terms are not ideally, excessively construed as formal meanings.

Embodiments of the present invention will be described below in more detail with reference to the accompanying drawings. In describing the invention, to facilitate the entire understanding of the invention, like numbers refer to like elements throughout the description of the figures, and a repetitive description on the same element is not provided.

FIG. 1 is a conceptual view illustrating an operating environment of an automatic working system using a sensor according to an embodiment of the present invention, and FIG. 2 illustrates an image of a pile of components, which is acquired through a visual sensor according to an embodiment of the present invention.

Referring to FIGS. 1 and 2, an automatic working system 100 having a sensor according to an embodiment of the present invention includes a pile image acquisition unit 110 (for example, a visual sensor and a position sensor) for recognizing a position of a component piled in a bin 101 and a picking unit 130 for picking the component 103 whose position is recognized.

Here, the working system using a sensor may acquire an image of a pile of components within the bin 101, as shown in FIG. 2, using the pile image acquisition unit 110 (for example, a visual sensor).

Then, the automatic working system 100 moves a component 102 picked by a picking unit 130 to a predetermined place (for example, an angle estimation worktable), acquires an image of the moved component using the component image acquisition unit 140 (for example, a visual sensor), and then estimates an angle of the component on the basis of the acquired image.

The automatic working system 100 using a sensor according to an embodiment of the present invention can perform precise component recognition and angle estimation through a component picking step and a component recognition step and effectively apply to a manufacturing line, thereby improving mounting of a component and enhancing productivity.

FIG. 3 is a flowchart illustrating a process of an automatic working method using a sensor according to an embodiment of the present invention.

Referring to FIG. 3, an automatic working system using a sensor (hereinafter, shortly referred to as an automatic working system) extracts a component to be picked from a pile of components, using a visual sensor (for example, a 3-D visual sensor) and a position sensor (S310).

The automatic working system picks the component extracted through step S310 to move the picked component to a predetermined place (S320).

Then, the automatic working system estimates an angle of the component moved through step S320 (S330).

The extracting of a component to be picked (S310) and the estimating of an angle of the moved component (S320) will be described below in details with reference to FIGS. 4 to 6.

FIG. 4 is a flowchart illustrating a process of extracting a component to be picked according to an embodiment of the present invention.

Referring to FIG. 4, the automatic working system acquires an image and depth information of a pile of components, using the visual sensor (S311).

Here, the automatic working system may acquire images of components using a visual sensor (for example, 3-D visual sensor) in an automatic worktable having a visual sensor and a lighting device to establish a database. That is, the database may be established by acquiring images and depth information about a variety of components piled at random while frequently changing angles of the components.

Then, the automatic working system extracts a region of at least one component to be picked, using the images and depth information acquired through step S311 (S313).

Here, the automatic working system sets as a standard model a model in which there is no change in angle in x-axis, y-axis, and z-axis directions, respectively, and extracts the region of the component similar to the standard model from the acquired component images as a picking object.

Then, the automatic working system calculates a local point of the region of the component extracted through step S313 and then measures an accurate distance to the component using a distance sensor (S315).

Here, the automatic working system may reduce an error as far as possible by performing step S315, thereby facilitating picking of a component.

The automatic working system picks the component out of the pile of components on the basis of the measured distance (S317).

Here, so as to easily perform the picking of the component in consideration of an error rate for the distance information or position of the component, the automatic working system may find a center point of the component and pick the component using a picking device (for example, a suction device, etc.)

FIG. 5 is a flowchart illustrating a process of estimating an angle of the moved component according to an embodiment of the present invention.

In the automatic working method according to an embodiment of the present invention, it is assumed that a database is established by classifying and learning components on the basis of their types and angles. The establishment of the database may be performed using the following procedure.

The automatic working system may acquire an image of a component through a visual sensor to establish a component image database. That is, the automatic working system may acquire information about an angle at which the component may be disposed and then acquire the image of the component to establish the component image database while changing a rotation angle along z-axis.

Here, the automatic working system may apply different illumination conditions on an hour-by-hour basis to acquire the image of the component under a variety of illumination environment to establish the database.

Also, the automatic working system performs an image smoothing process for reduction of illumination influence using the established component image database. Subsequently, the automatic working system extracts each edge of a component applying adaptive binarization and second derivative for a local region to detect an edge of the combined component, so as to extract edge elements of the component from the component image distorted due to shadow and illumination influence.

Next, the automatic working system detects and normalizes an edge surrounding a component region, and extracts statistical and structural features such as pixel distribution of a region of a component for the local region, a distance between the distributed pixels of the component in a vertical direction and a horizontal direction, and the number of cross points.

Here, the automatic working system removes a noise pixel existing in a region other than a region of interest (ROI) in which a component exists.

Subsequently, the automatic working system learns the component image obtained as a result of binarization and second derivative.

Here, the automatic working system may sub-classify components using a z-direction variable value divided by “a” degrees and then learn the components on the basis of their postures and angles.

Referring to FIG. 5, the automatic working system acquires an image of a moved component, using a visual sensor (S331).

Subsequently, the automatic working system detects an edge of the component from the image acquired through step S331 (S333).

Specifically, the automatic working system performs an image smoothing process for reduction of illumination and shadow influence in the image acquired through step S331 and detects an edge of the component applying adaptive binarization and second derivative for a local region in order to conserve component features vulnerable to distortion due to an ambient environment and extract a component region using the established component image database.

The automatic working system extracts features of the edge detected through step S333 (S337).

Then, the automatic working system recognizes a component on the basis of a component image data base previously established with respect to the features extracted through step S337 and estimates a difference angle in comparison with a component standard model selected on the basis of an angle and a posture (S339).

FIG. 6 is a flowchart illustrating a process of extracting a feature of an edge detected during the process of estimating an angle of a moved component of FIG. 5.

Referring to FIG. 6, the automatic working system normalizes the detected edge (S337-1).

Next, the automatic working system extracts statistical and structural features such as pixel distribution of a region of a component for a local region of the detected edge, a distance between the distributed pixels of the component in vertical and horizontal directions, and the number of cross points (S337-2).

Here, the automatic working system may remove a noise pixel existing in a region other than a region of interest (ROI) in which a component exists.

FIG. 7 is a block diagram illustrating a configuration of an automatic working system using a sensor according to an embodiment of the present invention.

Referring to FIG. 7, the automatic working system using a sensor according to an embodiment of the present invention may include a pile image acquisition unit 110, a processing unit 120, a picking unit 130, a component image acquisition unit 140, a component recognition unit 150, and a component learning unit 160.

First, the pile image acquisition unit 110 acquires an image of a pile of components and provides the acquired image to the processing unit 120.

Here, the pile image acquisition unit 110 may include a visual sensor, a position sensor, a distance sensor, etc.

The processing unit 120 extracts a region of at least of one component to be picked, using depth information of the component and the image of the component provided from the pile image acquisition unit 110.

Here, the processing unit 120 sets, as a standard model, a model in which there is no change in angle in x-axis, y-axis, and z-axis directions, respectively, and extracts, as a picking object, a region of a component similar to the standard model from the acquired component image.

Here, the processing unit 120 extracts a region of a component most similar to the standard model such that component picking may be facilitated.

Also, the processing unit 120 calculates a local point of the extracted region of the component and accurately measures the distance to the component using a distance sensor.

Here, the processing unit 120 calculates a local point of the extracted region of the component and accurately measures the distance, thereby reducing an error in component picking.

The picking unit 130 picks the component out of the pile of components on the basis of the distance measured by the processing unit 120 and move the picked component to a predetermined place.

Here, the picking unit 130 may find a central point of the component to pick the component with a suction device so as to facilitate the component picking in consideration of an error rate for the distance information or a position of the component.

The component image acquisition unit 140 acquires an image of the component moved to the predetermined place by the picking unit 130 using a visual sensor, and provides the acquired image of the component to the component recognition unit 150.

The component recognition unit 150 detects an edge of the component from the image of the component provided by the component image acquisition unit 140.

Specifically, the component recognition unit 150 performs an image smoothing process for reduction of illumination and shadow influence in the image acquired through the component image acquisition unit 140 and detects an edge of the component applying adaptive binarization and second derivative for a local area in order to conserve component features vulnerable to distortion due to an ambient environment and extract a component region.

Also, the component recognition unit 150 normalizes the detected edge and extracts statistical and structural features such as pixel distribution of a region of a component for a local area of the detected edge, a distance between the distributed pixels of the component in vertical and horizontal directions, and the number of cross points.

Here, the component recognition unit 150 may remove a noise pixel existing in a region other than a region of interest (ROI) in which a component exists.

Also, the component recognition unit 150 receives the previously established component image database from a component learning unit 160 with respect to the extracted features, recognizes the component on the basis of the received component image database, and estimates a difference angle in comparison with a component standard model in which the recognized component is classified on the basis of its angle.

The component learning unit 160 may acquire the image of the component from the component image acquisition unit 140 to establish the component image database. That is, the component learning unit 160 may acquire information about an angle at which the component may be disposed and then acquire the image of the component to establish the component image database while changing a rotation angle along z-axis.

Here, the component learning unit 160 applies different illumination conditions on an hour-by-hour basis to acquire the image of the component under a variety of illumination environment to establish a database, and performs an image smoothing process for reduction of illumination influence using the established component image database.

Also, after the image smoothing process, the component learning unit 160 extracts each edge of the component applying adaptive binarization and second derivative for a local area to detect the edge of the combined component part, so as to extract edge elements of the component from the component image distorted due to shadow and illumination influence.

Also, the component learning unit 160 detects and normalizes an edge surrounding the component region, and then extracts statistical and structural features such as pixel distribution of a region of a component in the local area, a distance between the distributed pixels of the component in a vertical direction and a horizontal direction, and the number of cross points.

Here, the component learning unit 160 removes a noise pixel existing in a region other than a region of interest (ROI) in which the component exists.

Also, the component learning unit 160 performs a learning process on the component image obtained as a result of binarization and second derivative. Here, in the learning process, components are sub-classified using a z-direction variable value divided by “a” degrees and then learned on the basis of their postures and angles.

The automatic working system 100 using a sensor according to an embodiment of the present invention can perform precise component recognition and angle estimation through a component picking step and a component recognition step and effectively apply to a manufacturing line, thereby improving mounting of a component and enhancing productivity.

The working method having a sensor and the working system for performing the same according to an embodiment of the present invention include extracting approximate position and distance information about a component to be picked, picking the component, moving the picked component to a worktable, recognizing an angle of the component, and then performing assembly and packing.

Accordingly, the working method using a sensor and the working system for performing the same according to an embodiment of the present invention can perform precise component recognition and posture estimation by two steps: a component picking step and a component recognition step, and effectively apply to a manufacturing line, thereby improving mounting of a component and enhancing productivity.

While the example embodiments of the present invention and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations may be made herein without departing from the scope of the invention. 

What is claimed is:
 1. A working method using a sensor, comprising: extracting an object to be picked from a pile of objects using the sensor; picking the extracted object to move the picked object to a predetermined place; and estimating an angle of the moved object in the current position using the sensor.
 2. The working method of claim 1, wherein the extracting of the object to be picked comprises: acquiring an image and depth information of the pile of objects using a visual sensor; extracting a region of the object to be picked using the acquired image and depth information of the pile of objects; calculating a local point of the extracted region of the object and measuring a distance to the extracted object using a distance sensor; and picking the extracted object on the basis of the measured distance to move the picked object to a predetermined place.
 3. The working method of claim 2, wherein the extracting of the region of the object comprises extracting the region of the object in a model most similar to a standard model in which there is no change in angle in x-axis, y-axis, and z-axis directions, respectively, using the acquired image and depth information of the object.
 4. The working method of claim 1, wherein the estimating of an angle of the moved object in the current position using the sensor comprises: acquiring an image of the moved object using the sensor; detecting an edge of the object from the acquired image; extracting a feature of the detected edge; and comparing the extracted feature of the edge with a predetermined object standard model to estimate an angle of the moved object in the current position.
 5. The working method of claim 4, wherein the detecting of an edge of the object from the acquired image comprises detecting an edge of the object by performing an image smoothing process on the acquired image and applying adaptive binarization and second derivative for a local region.
 6. The working method of claim 4, wherein the extracting of a feature of the detected edge comprises: normalizing the detected edge; and extracting statistical and structural features on the basis of at least one of a pixel distribution of a region of the object, a distance between the distributed pixels of the object, and the number of cross points with respect to the detected local region of the edge.
 7. An automatic working system using a sensor comprising: a pile image acquisition unit configured to acquire and provide an image and depth information of a pile of objects using a visual sensor; a processing unit configured to extract a region of at least one object to be picked using the acquired and provided image and depth information of the objects, calculate a local point of the extracted region of at least one object, measure a distance to the at least one object using the sensor, and provide the measured distance; a picking unit configured to pick the at least one object on the basis of the measured distance, which is provided, to move the at least one object to a predetermined place; an object image acquisition unit configured to acquire an image of the moved object; and an object recognition unit configured to detect an edge of the object from the acquired image of the object, extract a feature of the detected edge, compare the extracted feature with a predetermined object standard model, and estimate an angle of the picked object in the current position.
 8. The working system of claim 7, wherein the pile image acquisition unit is configured to extract a region of the at least one object in a model most similar to a standard model in which there is no change in angle in x-axis, y-axis, and z-axis directions, respectively, using the acquired and provided image and depth information of the object.
 9. The working system of claim 7, wherein the object acquisition unit is configured to detect an edge of the object by performing an image smoothing process on the image of the moved object and applying adaptive binarization and second derivative for a local region.
 10. The working system of claim 7, wherein the object recognition unit is configured to normalize the detected edge and extract statistical and structural features on the basis of at least one of a pixel distribution of a region of the object, a distance between the distributed pixels of the object, and the number of cross points with respect to the detected local region of the edge. 